My '03 Civic's exhaust manifold is likely cracked. In preparation for its repair, can folks here opine on the following options?

-- Buy an OEM exhaust manifold (includes converter) for some $500 via bkhondaparts.com. There's a refundable core charge. Shipping may cost me. Pros: Converter will last a long time. Cons: Expensive and may crack again (and again... ).

-- Stop by a muffler shop and see if they can weld the old one. Pros: Cheap. Cons: Could break again.

-- Buy an aftermarket one for about $300. I should be able to sell the old converter for its metals at an appropriate scrap yard. Pros: Cheap. Cons: Converter won't last as long as a new OEM one.

-- Scour the junkyard, but I am not optimistic. I think the catalytic converters are removed for their precious metal value. Pros: cheap. Cons: It may crack again; short life of the converter.

-- Retrofit an EX manifold (no converter). Install a new converter in the exhaust piping. Pros: Less expensive to replace the manifold if and when it cracks again. Cons: Engineering design and creativity may be required for the converter retrofit, maybe taking a bit more time than I want to give.

Honda shops say this is pretty common but the warranty has not been extended for the 01-05 Civics.

 

The Magnaflow direct-fit aftermarket replacement actually would be a great option. You could look around to find a salvage yard that will take your factory catalytic converter for money, then purchase the Magnaflow. Its going to last you a lot longer then a factory replacement.

http://www.carid.com/2001-honda-civi...r-3620079.html

 

I see the LX one costs $496 and so is close to the OEM cost, but I hear you about it lasting longer. Thank you for the link and recommendation.

 

I believe RockAuto.com had the Magnaflow direct replacement for sale as well, but at a much more friendly price.

 

Toyomatt, thank you. I may go the aftermarket, stainless steel route in a year or so.

I took off the heat shield yesterday and ran the car to confirm where the crack is. It appears the only crack is at the joint where the passenger side cylinder's (#4's) exhaust pipe is welded to the plate of the manifold. Based on other people's reports, it seems like a product callled Thermosteel is worth a try to patch it. I need to wait until spring or so to use the Thermosteel, since the curing requires 80 to 100 degees F for several hours.

I spoke with Honda at its manufacturer number. First I reported this for my specific Honda. If Honda gets enough reports, it may extend the warranty. Second I asked what the warranty on a new OEM exhaust manifold/converter is. Honda said 12 months or 12,000 miles. This offers little incentive to buy a second OEM one that sure, will crack too. Third I confirmed there has been no design change to the manifold, such that OEM parts dealers are selling a better quality one than was put on at the factory.

The good news is that the actual labor for replacing the manifold is minuscule, as long as one uses some PB Blaster and is careful when removing the associated heat-cycled bolts.